Pic. 5.35. Steering components
Checking and adjusting before disassembly
Pic. 5.36. Fixing the steering mechanism in a vice
Install soft metal pads on the vise jaws (brass or aluminum plates) to prevent damage to the steering gear and secure it in a vise (pic. 5.36).
Attention! When installing the steering mechanism in a vise, fix it so that the jaws of the vise are aligned with the installation location of the mounting bracket. Another method of fastening in a vise may damage the steering gear.
Checking the total torque of the steering gear
(steering gear shaft preload)
Pic. 5.37. Rack and pinion steering gear rotation
To check the total rotation torque of the steering gear using a special wrench, rotate the rack and pinion steering gear within one revolution for 4-6 seconds (pic. 5.37).
Total rotation torque of steering gear (nominal value): 0.6–1.3 Nm.
Note. Measure the torque of the drive gear with the full travel of the steering rack.
If the measured value does not correspond to the nominal value, first adjust the position of the steering rack stop cover and then check the total torque of the steering gear again.
If the total drive gear torque cannot be adjusted, check the stop cover, stop spring and steering rack stop and replace parts if necessary.
Checking resistance to rotation of the tie rod joint
Make 10 strong turns of the tie rod end.
Pic. 5.38. Measuring resistance to rotation of the tie rod joint
Using a spring dynamometer, measure the resistance to rotation of the tie rod joint (pic. 5.38).
Moment of resistance to rotation of the tie rod joint (nominal value): 8–22 N (2–5 Nm).
If the measured value exceeds the nominal value, replace the tie rod assembly.
Attention! If the measured value is less than the nominal value, however, the steering rod turns smoothly, without excessive play, then such a tip is suitable for operation. If the measured value is less than 4.3 N (1 Nm), replace the tie rod assembly.
Checking the protective cover
Check the protective cover for damage or deterioration.
Check that the protective cover is properly attached.
If defects are found in the protective cover, replace it with a new one.
Disassembly
Pic. 5.39. Removing the tie rod end
Remove the tie rod end (pic. 5.39).
Pic. 5.40. Removing the protective cover of the ball joint
Clamp the tie rod end in a vise, then remove the ball joint boot (pic. 5.40).
Pic. 5.41. Removal of a large collar of fastening of a protective cover of steering draft
Remove the large clamp securing the protective cover of the tie rod (pic. 5.41).
Pic. 5.42. Removal of a small collar of fastening of a protective cover of steering draft
Remove the small collar securing the protective cover of the steering rod (pic. 5.42).
Pull off a protective cover from the case of the steering mechanism on steering draft.
Note. When replacing the protective boot, check that there is no rust on the steering rack.
Disconnect the steering tubes from the valve body and steering gear and remove them.
Slowly moving the rack, drain the working fluid from the steering gear housing.
Pic. 5.43. Lock washer caulking
Using a chisel, chisel out the lock washer that secures the tie rod and steering rack (pic. 5.43).
Pic. 5.44. Removing the tie rod from the steering rack
Remove the tie rod from the steering rack (pic. 5.44).
Attention! Be careful when removing the tie rod from the steering rack, do not bend the rack.
Pic. 5.45. Removing the rack stop cover jam nut
Loosen the lock nut of the rack stop cover (pic. 5.45).
Pic. 5.46. Removing the rack stop covers
Remove rack stop covers with a 14mm tool head (pic. 5.46).
Pic. 5.47. Rail components
Remove the rack stop spring, rack stop, rack stop cover and bushing from the steering box (pic. 5.47).
Pic. 5.48. Valve body mounting bolts
Loosen the two mounting bolts and remove the valve body assembly (pic. 5.48).
Pic. 5.49. Rotate the rack travel stop clockwise
Turn the rack travel stop clockwise until the end of the retaining ring comes out of the slot in the steering gear housing (pic. 5.49).
Pic. 5.50. Removing the retaining ring
Once the end of the retaining ring is out of the slot in the steering gear housing, turn the rack travel stop counterclockwise and remove the retaining ring (pic. 5.50).
Pic. 5.51. Removing the O-ring
Remove the o-ring from the rack support sleeve (pic. 5.51).
Pic. 5.52. Removing the gland
Remove the oil seal from the rack support sleeve (pic. 5.52).
Pic. 5.53. Removing the pinion and valve assembly from the valve body
Using a plastic-faced hammer, lightly tap the pinion gear and valve assembly out of the valve body (pic. 5.53).
Using the special tool, remove the gland and ball bearing from the valve body.
Attention! Be careful not to damage the inner surface of the pinion cylinder in the steering box.
Pic. 5.54. Extraction of an epiploon from the case of the steering mechanism
Using the special tool, remove the oil seal from the steering gear housing (pic. 5.54).
Attention! Be careful not to damage the inner surface of the rack cylinder in the steering box.
Checking the steering rack
Check for wear or damage on the steering rack teeth.
Check the contact surface for oil seal installation for excessive wear or damage.
Pic. 5.55. steering rack
Check the straightness of the steering rack (no bending or twisting) (pic. 5.55).
Check the O-ring for excessive wear or damage.
Check the oil seal for excessive wear or damage.
Pic. 5.56. pinion gear
Check drive gear teeth for wear or damage (pic. 5.56).
Check the contact surface for oil seal installation for excessive wear or damage.
Check the O-ring for excessive wear or damage.
Check the oil seal for excessive wear or damage.
Check the smoothness of rotation and the absence of extraneous noise during the operation of the bearings.
Check for excessive play in the bearings.
Check that the needles are not falling out of the needle bearing.
Check for damage to the inner surface of the steering gear housing cylinder.
Check protective covers for wear, cracks or tears.
Assembly
Apply the recommended PSF-3 fluid to the lip of the steering rack oil seal around its entire circumference.
Pic. 5.57. Scheme of installation of the restrictive washer and stuffing box
Establish a restrictive washer and an epiploon in the case of the steering mechanism, as it is shown in drawing 5.57.
Apply the recommended working fluid to the steering rack bearing bushing seal around its entire circumference.
Pic. 5.58. Scheme of installing the stuffing box on the support sleeve of the rail
Install the oil seal on the rack support sleeve (pic. 5.58).
Apply the recommended hydraulic fluid to the O-ring and install it to the steering rack mounting bushing.
Apply the recommended grease to the steering rack teeth.
Recommended lubricant: SAE J310, NLGI #2 General Purpose.
Pic. 5.59. Air vent
Note. Do not fill the steering rack vent hole with grease (pic. 5.59).
Pic. 5.60. Installing rail components
Insert the rack into the steering box, then install the rack support bushing and rack travel stop (pic. 5.60).
Pic. 5.61. Retaining Ring Installation Diagram
Insert the circlip into the rack travel stop hole through the hole in the steering box when the holes are aligned. Rotate the rack travel stop and finally secure the circlip (pic. 5.61).
Attention! After installing the retaining ring, its ends should not be visible through the hole in the steering gear housing.
Pic. 5.62. Installing the gland and ball bearing in the valve body
Using the special tool, install the oil seal and ball bearing into the valve body (pic. 5.62).
Pic. 5.63. pinion gear
Apply the recommended fluid to the pinion and valve assembly, then install them into the valve body (pic. 5.63).
Pic. 5.64. Installing the valve body and O-ring to the steering gear housing
Apply the recommended working fluid to the oil seal and install it in the steering gear housing. Install valve body assembly and o-ring to steering gear housing (pic. 5.64).
Install a new lock washer and tie rod. Caulk the edges of the lock washer in two places on the tie rod.
Note. Get in two places the antennae of the lock washer in the recesses of the steering rod.
Pic. 5.65. Lock washer installation diagram
Always replace the lock washer with a new one before installation (pic. 5.65).
Pic. 5.66. Rail assembly
Establish an insert, an emphasis, a spring and a cover of an emphasis of a lath in the case of the steering mechanism in the sequence shown in drawing 5.66.
Apply turning into «rubber» sealant (semydrying sealant) on the threaded part of the rack stop cover before installing it.
Pic. 5.67. Installing the Rack Stop Cover
Center the rack, then insert the rack stop cover into the steering box. Using the special tool, tighten the rack stop cover to 15 Nm (pic. 5.67).
Unscrew the rack stop cover by 30–60°and tighten the lock nut of the rack stop cover with a nominal torque of 50–70 Nm.
Install and tighten the steering tubes to the specified torque, then install the rubber mounts in place with special adhesive (adhesive).
Apply the recommended silicone grease to the tie rod end protector small collar (into the groove on the pull).
Install a new large tie rod boot clamp.
Note. Before installing the tie rod boot, always replace the large boot collar with a new one.
Pic. 5.68. Installation of a protective cover of steering draft
Install the tie rod boot in place without twisting it (pic. 5.68).
Pic. 5.69. Lubrication points
Fill the inner cavity of the protective boot of the ball joint of the tie rod end (A) and the working edge of the ball joint (B) recommended lubricant (pic. 5.69).
Apply the recommended sealant to the sealing lip of the protective boot and secure it to the ball joint with a clamp.
Recommended lubricant:
- A - POLY LUB GLY 801K or equivalent;
- B - SHOWA SUNLIGHT MB2 or equivalent.
Recommended sealant for the sealing lip of the protective boot: THREE BOND.
Pic. 5.70. Tie rod end locknut
Wrap the left and right tie rod ends so that the length of the protruding part of the rod on the left and right is the same and corresponds to the nominal value. Lock in position with locknut (pic. 5.70).
Length of the protruding part of the steering rod: 204.5 mm.
Check the total torque of the steering gear (steering gear shaft preload).
Installation
Pic. 5.71. Steering gear installation
Install the steering assembly through the right wheel arch (pic. 5.71).
Install the steering shaft guard support plate.
Connect the steering shaft boot to its base plate with a new band clamp.
Connect the steering shaft and steering column assembly to the steering gear assembly.
Install the rest of the parts in the reverse order of removal.
Bleed air from power steering hydraulic system.